On-vehicle image processing device

ABSTRACT

An object of the present invention is to provide is an on-vehicle image processing device that achieves low cost and provides high mounting accuracy and high electrical adjustment accuracy during a manufacturing process. The on-vehicle image processing device includes a first imaging section, a second imaging section, and an enclosure having the first imaging section at one end and the second imaging section at the other end. The on-vehicle image processing device generates a range image from images captured by the first and second imaging sections. The on-vehicle image processing device further includes an enclosure reference surface that comes in contact with an equipment jig during manufacture, the enclosure reference surface being provided at two locations between the first and second imaging sections.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/234,182 filed Dec. 27, 2018, which is a continuation of U.S.application Ser. No. 14/418,145 filed Jan. 29, 2015, now U.S. Pat. No.10,214,155 issued Feb. 26, 2019, which is a National Stage of PCTInternational Application No. PCT/JP2013/066772, filed Jun. 19, 2013,which claims priority from Japanese Patent Application No. 2012-169073,filed on Jul. 31, 2012, the disclosures of which are expresslyincorporated by reference herein.

TECHNICAL FIELD

The present invention relates to an on-vehicle image processing devicehaving an image sensor.

BACKGROUND ART

An on-vehicle camera (hereinafter referred to as the stereo camera),serving as an on-vehicle image processing device, uses a pair of imagescaptured by two imaging sections, calculates the distance to a target bytriangulation, and recognizes the target accordingly, is now beginningto be applied to an on-vehicle system for facilitating safe driving of avehicle.

In an environment where the device is mounted on vehicles, inparticular, it is necessary to properly measure the distance to a remotetarget and recognize it due to application requirements that demand thedetection of preceding vehicles, humans, and obstacles in order to takesafety precautions.

Further, when a stereo image processing system is to be used as anon-vehicle system, it is also requested that the system be compact,low-priced, and highly reliable.

The above system generally includes a dedicated LSI that checks pixelinformation included in a pair of images, identifies positions of pixelsindicative of feature points common to the pair of images, anddetermines the number of displaced pixels indicative of feature pointsin the pair of images (hereinafter referred to as disparity).

As the above principles apply, it is ideal that no displacement exceptdisparity is found in the pair of images. All imaging means need to bestructured so that they can be accurately adjusted to avoid anydiscrepancies in optical characteristics and signal characteristics andmaintained in the accurately adjusted state.

An invention disclosed in Patent Document 1 is related to theabove-described background art. Patent Document 1 describes that anon-vehicle camera formed of a pair of cameras includes a camera stay andan installation area. The installation area is structured integrallywith the camera stay and fastened to a chassis of a vehicle, the camerastay holding the pair of cameras in predetermined positions. Theon-vehicle camera is securely screwed into the installation holes in thechassis of the vehicle by use of three installation holes disposed inthe installation area and of three screws. As the camera is screwed inthis way, it is possible to accurately maintain the relative positionsof the pair of cameras.

Patent Document 2 describes a compound-eye camera. Two or more lightrays are emitted from two or more light sources disposed at a positionat which the compound-eye camera is mounted. A target is disposed at anintersection of the two or more light sources. The compound-eye camerais adjusted by photographing the target. This adjustment makes itpossible to accurately adjust the optical axis and focus of thecompound-eye camera.

PRIOR ART LITERATURE Patent Documents

Patent Document 1: JP-2009-68906-A

Patent Document 2: JP-2002-218504-A

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

To improve the measurement accuracy of a stereo camera, it is necessaryto increase the accuracy of the relative positions of left and rightimaging sections as mentioned above. However, simply increasing themechanical accuracy of the enclosure will not result in adequateperformance of the stereo camera. Therefore, electrical adjustments needto be made (corrections need to be made with images captured by thestereo camera) during a manufacturing process.

As such being the case, the stereo camera needs to be adjusted while itis mounted on a manufacturing equipment jig with higher accuracy thanthat when the stereo camera is mounted on a vehicle during themanufacturing process.

An idea described in Patent Document 1 is for mounting the stereo cameraon a vehicle with high accuracy and making the enclosure unlikely todeform due to temperature changes. However, this idea is not adequate toprovide high mounting accuracy for stereo camera adjustment during amanufacturing process. Further, Patent Document 2 states that thecompound-eye camera is accurately mounted on a reference surface of ajig. However, Patent Document 2 does not describe in detail a method ofaccurately mounting the compound-eye camera.

In view of the above circumstances, the present invention has an objectto provide an on-vehicle image processing device that achieves low costand provides high mounting accuracy with respect to a manufacturingequipment jig in order to increase the accuracy of electricaladjustments during a manufacturing process.

Means for Solving the Problems

In order to solve the above problems, the on-vehicle image processingdevice according to the present invention includes a first imagingsection, a second imaging section, and an enclosure having the firstimaging section at one end and the second imaging section at the otherend. The on-vehicle image processing device generates a range image fromimages captured by the first and second imaging sections. The on-vehicleimage processing device further includes an enclosure reference surfacethat comes in contact with an equipment jig during manufacture, theenclosure reference surface being provided at two locations between thefirst and second imaging sections.

Effect of the Invention

The present invention provides an on-vehicle image processing devicethat achieves low cost and provides high mounting accuracy on amanufacturing equipment jig in order to increase the accuracy ofelectrical adjustments during a manufacturing process.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram illustrating an exemplary enclosure structure of anon-vehicle image processing device according to a first embodiment ofthe present invention.

FIGS. 2A and 2B are diagrams illustrating an exemplary enclosurestructure of the on-vehicle image processing device according to asecond embodiment of the present invention.

FIG. 3 is a diagram illustrating another exemplary enclosure structureof the on-vehicle image processing device according to the secondembodiment.

FIG. 4 is a diagram illustrating an exemplary enclosure structure of theon-vehicle image processing device according to a third embodiment ofthe present invention.

MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will now be described withreference to the accompanying drawings.

First Embodiment

An embodiment of an on-vehicle image processing device according to thepresent invention will be described below. FIG. 1 shows an exemplaryenclosure structure of a stereo camera that serves as an on-vehicleimage processing device. The exemplary enclosure structure shown in FIG.1 has an enclosure reference surface 13 that comes into contact with anequipment jig during manufacture.

As shown in FIG. 1, the stereo camera, serving as the on-vehicle imageprocessing device according to the present invention, includes twoimaging sections 12 (first and second imaging sections) and an enclosure11. The enclosure 11 has the first imaging section at one end and thesecond imaging section at the other end. A range image (disparity image)is generated from images captured by these two imaging sections.

The imaging sections 12 each include an image sensor, a lens, left andright imaging circuit boards, and a signal processing circuit board. Thelens causes the image sensor to form an image representing the visualinformation about the outside world. The imaging circuit boards have aprocessing function of introducing, into an image processing LSI, imageinformation formed on the image sensor. The signal processing circuitboard drives the image sensor.

The enclosure 11 includes a processing circuit board, a vehicle-mountingsurface 15, a reference hole 14, and an enclosure reference surface 13.The processing circuit board includes a circuit that causes the imageprocessing LSI to extract a target in accordance with the imageinformation sent from the imaging circuit boards and calculates thedistance to and the size of the target. The vehicle-mounting surface 15has a base and holes into which screws are introduced for fixing theenclosure to a vehicle. The reference hole 14 engages with a pin on thevehicle to ensure that the stereo camera, serving as the on-vehicleimage processing device, is accurately oriented when it is mounted onthe vehicle. The enclosure reference surface 13 comes into contact withan equipment jig when the stereo camera is manufactured.

After the stereo camera is mounted on the equipment jig, the image of arandom pattern needs to be captured for electrical adjustments of thestereo camera. To generate accurate adjustment data from the pattern,the imaging direction (hereinafter referred to as the optical axis) ofthe stereo camera needs to be fixed in a desired direction by causingthe up-down, left-right, and front-rear positions of the enclosurereference surface 13 to coincide with desired positions when it ismounted on the equipment jig.

Further, the orientation of the optical axis in manufacturing equipmentis most likely to be affected by displacement in the rotating directionof the up-down, left-right, and front-rear axes, the displacementarising when the stereo camera is mounted on the equipment jig.Therefore, such displacement needs to be minimized.

In a case where a plurality of reference holes 14 for mounting vehiclesare used to mount the stereo camera on the equipment jig duringmanufacture, the intervals between the plurality of reference holes 14for vehicle-mounting would be short because the plurality of referenceholes 14 for vehicle-mounting are generally centered on the center ofthe enclosure 11. Accordingly, a larger mounting error would occur ifthe stereo camera is mounted on the equipment.

The present invention is characterized in that two enclosure referencesurfaces 13 are provided between the first and second imaging sectionsand brought into contact with the equipment jig during manufacture. Morespecifically, the enclosure reference surface 13 is disposed between thefirst imaging section on one hand and the middle of the first and secondimaging sections (or the vehicle-mounting surface 15) on the other aswell as disposed between the second imaging section and the middle (orthe vehicle-mounting surface 15). In other words, two enclosurereference surfaces 13 are provided on the enclosure 11 or the imagingsections 12 in addition to the plurality of reference holes 14 forvehicle-mounting, as shown in FIG. 1. The interval between the twoenclosure reference surfaces 13 is maximized, or more specifically, thetwo enclosure reference surfaces 13 are positioned relatively close tothe imaging sections (a first enclosure reference surface is positionednear the middle of the first imaging section and the vehicle-mountingsurface but closer to the first imaging section, and a second enclosurereference surface is positioned near the middle of the second imagingsection and the vehicle-mounting surface but closer to the secondimaging section), so that the mounting error will be reduced to ⅓, themounting error conventionally occurring at a rate of ½ when the stereocamera is mounted on the equipment. It is preferred that the intervalbetween the two enclosure reference surfaces 13 be maximized bydisposing them at the maximum possible distance from each other in thelongitudinal direction of the enclosure 11. It is preferable that thetwo enclosure reference surfaces 13 be positioned near the lenses of theimaging sections 12, for example.

With reference to FIG. 1, the enclosure reference surfaces 13 arepositioned at the front side—that is, toward the imaging direction ofthe imaging sections 12 of the enclosure 11.

In order to minimize the mounting error, it is preferred that the twoenclosure reference surfaces 13 be positioned outward of the lenses ofthe imaging sections 12. However, the imaging sections 12 have to bemechanically adjusted, for instance, by adjusting the focus of eachlens. Therefore, it is most appropriate that the two enclosure referencesurfaces 13 be positioned as outward as possible within the limits ofthe enclosure 11.

When the contact with the equipment jig is taken into consideration, itis preferred that the enclosure reference surface 13 be rectangular inshape as shown in FIG. 1.

It should be noted, however, that the enclosure reference surface 13 canbe used not only as the contact with an equipment jig for adjustment butalso as the contact with a jig for processing.

Further, as the enclosure 11 is generally made of aluminum die cast, theenclosure reference surface 13 may also serve as an extrusion pinposition for removing the enclosure from a die cast mold.

In the above cases, the enclosure reference surface 13 may be circularin shape as well.

The enclosure reference surface 13 that is to be processed and removedfrom a mold may be used as is, so that the enclosure reference surface13 is as parallel a surface as possible. However, the degree ofparallelism of the enclosure reference surface 13 can be increased bycutting or grinding.

The stereo camera needs to be properly positioned when it is mounted.Therefore, as shown in FIG. 1, the enclosure reference surface 13 needsto be big enough to come into contact with the equipment jig at two ormore points.

In the above instance, only one enclosure reference surface 13 maysuffice. However, as the enclosure reference surface 13 needs to beprocessed, it is preferred that the size of the enclosure referencesurface 13 be minimized to reduce the cost.

Consequently, it is preferred that two or more enclosure referencesurfaces 13 be provided and minimized in size.

When two enclosure reference surfaces 13 are to be provided andaccurately mounted on the equipment, it is most appropriate that they beparallel and flush with each other. If the enclosure is shaped so thatthey cannot be flush with each other, they may be merely parallel toeach other.

Second Embodiment

A second embodiment of the present invention will now be described withreference to an exemplary structure in which a certain enclosurereference surface is provided in addition to the enclosure referencesurface 13 shown in FIG. 1. The second embodiment applies to a casewhere the surface brought into contact with the equipment jig duringmanufacture is positioned upward (on the surface to be mounted on thevehicle).

Elements that perform the same functions and are designated by the samereference numerals as the elements shown in FIG. 1 will not beredundantly described.

FIG. 2A shows an example in which an upper enclosure reference surface21 is disposed on the top of the enclosure 11 (on the surface to bemounted on the vehicle), that is, toward the vehicle-mounting surface15, in addition to the enclosure reference surface 13.

FIG. 2B shows an example in which a front enclosure reference surface22, which is an integrated combination of the enclosure referencesurface 13 and the upper enclosure reference surface 21, is provided. Inthis case, the surface brought into contact with the equipment jigduring manufacture is disposed on the top of the front enclosurereference surface 22 (on the surface to be mounted on the vehicle),namely on the top of a front portion of the enclosure 11 in a directionin which the imaging sections 12 form an image.

FIG. 3 shows an example in which a lateral enclosure reference surface31 is provided in addition to the enclosure reference surface 13. Thelateral enclosure reference surface 31 is disposed on a lateral side ofthe reference hole 14, which is provided on the middle of the enclosure11, and on a lateral side of the vehicle-mounting surface 15. Morespecifically, the lateral enclosure reference surface 31, which isprovided on the middle, is disposed on a lateral side of one of twovehicle-mounting surfaces 15 that are disposed toward the imagingdirection of the imaging sections 12, and is disposed on a lateral sideof the other vehicle-mounting surface 15 that is disposed toward adirection opposite to the imaging direction.

As is the case with the enclosure reference surface 13, the upperenclosure reference surface 21 may also use the vehicle-mounting surface15 that comes into contact with the vehicle at times ofvehicle-mounting. However, the surface brought into contact with thevehicle is centered on the middle of the enclosure 11, as is the casewith the enclosure reference surface 13. Therefore, in order to disposethe vehicle-mounting surface 15 at an adequate distance whereverpossible, it is preferred that the upper enclosure reference surface 21be provided in addition to the vehicle-mounting surface 15 which comesinto contact with the vehicle, as shown in FIG. 2A.

In the above instance, it is most appropriate that the two upperenclosure reference surfaces 21 be parallel and flush with each other.Even if they cannot easily be flush with each other, the same advantagecan be obtained as long as they are parallel to each other.

As shown in FIG. 2B, when the upper enclosure reference surface 21 andthe enclosure reference surface 13 are to be provided, they may beintegrated and provided as the front enclosure reference surface 22.This makes it possible to reduce the installation space for theenclosure reference surface and decrease the size of a stereo cameraenclosure when it is mounted on the vehicle.

As shown in FIG. 3, the lateral enclosure reference surface 31 may bedisposed in the front and in the rear. In the present embodiment, one ofthe two lateral enclosure reference surfaces 31 is disposed on thelateral side of one of the two vehicle-mounting surfaces 15 that arepositioned at the front, and the other lateral enclosure referencesurface 31 is disposed on the lateral side of one of two reference holes14 that are positioned at the back. Alternatively, however, either oneof the two lateral enclosure reference surfaces 31 may be omitted. Analternative for example is to dispose only one lateral enclosurereference surface 31 on the lateral side of one of the two referenceholes 14 that are positioned at the back.

Third Embodiment

A third embodiment of the present invention will now be described withreference to an exemplary structure in which an enclosure reference hole41 is provided instead of the enclosure reference surface 13.

Elements that perform the same functions and are designated by the samereference numerals as the elements shown in FIG. 1 will not beredundantly described.

FIG. 4 shows an example in which the enclosure reference hole 41,instead of the enclosure reference surface 13 and the lateral enclosurereference surface, is disposed on the side of the vehicle-mountingsurface 15 of the imaging sections 12, the enclosure reference hole 41serving as an enclosure reference surface.

Being positioned with relation to the equipment jig, two enclosurereference holes 41 should preferably be provided as shown in FIG. 4.Further, the enclosure reference holes 41 may be both shaped as either aperfect circle or an oval. However, as a pin to be inserted is used asthe equipment jig, it is preferred, from the viewpoint of engagement,that one enclosure reference hole 41 be shaped as a perfect circle whilethe other be shaped as an oval.

The enclosure reference hole 41 may be disposed on the enclosure 11instead of the imaging sections 12. In this case, too, it is preferredthat the two enclosure reference holes 41 be positioned at the maximumpossible distance from each other.

Moreover, the enclosure reference hole 41 may be formed integrally withthe upper enclosure reference surface 21. This makes it possible toachieve positioning in the front-rear direction, up-down direction, andleft-right direction.

The present invention is not limited to the foregoing embodiments butmay be variously modified. The foregoing embodiments have been describedin detail to facilitate the understanding of the present invention. Thepresent invention is not necessarily limited to a configuration havingall the above-described elements.

Some of the elements included in a certain embodiment may be replaced bythe elements of another embodiment. Further, the elements included in acertain embodiment may be added to the elements included in anotherembodiment.

Furthermore, some elements of each embodiment may be subjected to theaddition of other elements, deleted, or replaced by other elements.

DESCRIPTION OF REFERENCE NUMERALS

-   11 . . . Enclosure-   12 . . . Imaging section-   13 . . . Enclosure reference surface-   14 . . . Reference hole-   15 . . . Vehicle-mounting surface-   21 . . . Upper enclosure reference surface-   22 . . . Front enclosure reference surface-   31 . . . Lateral enclosure reference surface-   41 . . . Enclosure reference hole

The invention claimed is:
 1. A stereo vision system for vehiclecomprising: a first imaging section, and a second imaging section; anenclosure having the first imaging section arranged at one end and thesecond imaging section arranged at another end thereof; a plurality offirst projections that project from the enclosure in a first directionand a plurality of second projections that project from the enclosure ina second direction opposite to the first direction, each of the firstand second projections including a vehicle-mounting surface; a pair ofupper reference surfaces disposed on an upper surface of the enclosure,one of which is disposed adjacent to the first imaging section andanother of which is disposed adjacent to the second imaging section; anda pair of enclosure reference surfaces disposed on a same side of theenclosure as the first and second imaging sections and disposed closerto the vehicle-mounting surfaces than the upper reference surfaces;wherein the upper reference surfaces and the enclosure referencesurfaces are references for a jig for electrical adjustment; each of theplurality of first and second projections includes a cut or groundsurface; wherein the cut or ground surface of each of the first andsecond projections is exposed in a state in which the stereo visionsystem is assembled.
 2. The stereo vision system according to claim 1,wherein the first projections and the second projections are exposed inthe state in which the stereo vision system is assembled.
 3. The stereovision system according to claim 1, wherein the cut or ground surface ofeach of the first projections is located on a first side thereof; andwherein the cut or ground surface of each of the second projections islocated on a second side thereof.
 4. The stereo vision system accordingto claim 3, wherein the first side of each of the first projections is asurface other than a surface positioned on a projecting direction of thefirst projections; and wherein the second side of each of the secondprojections is a surface other than a surface positioned on projectingdirection of the second projections.
 5. The stereo vision systemaccording to claim 4, wherein the cut or ground surface of each of thefirst and second projections is cut.
 6. The stereo vision systemaccording to claim 1, wherein the cut or ground surface of each of thefirst and second projections is cut.